Method and apparatus for winding cones with equal thread lengths



T. w. GEITENBEEK 2,871,569 METHOD AND APPARATUS FOR WINDING COMES WITH EQUAL THREAD LENGTHS Filed Dec. .14, 1955 Feb. 3, 1959 D/AMETER- "D FIG, 1

FIG. 3

m m m THEODOOR WILLEM GEiTENBEEK ATTORNEY the maximum compactness observed in practice.

METH

Theodoor W. Geitenbeek, Ede, American Enka Corporation, tion of Delaware I Application December 14, 1955, Serial No. 553,129

Claims priority, application Netherlands December 17, 1954 8 Claims. (Cl. 33-136) Netherlands, assignor to Erika, N. C., a corpora- This invention relates to Winding machines, and more particularly to a novel method and apparatus for use in conjunction therewith.

In certain winding operations it is necessary that the length of thread which is wound upon each of a series of individual cones remain relatively constant. Heretofore, difficulty has been encountered in attempting to apply substantially the same length of thread to each of such cones.

While certain present-day devices such as cross-winding machines have used systems which interrupt the winding operation at the instant when the thread package attains a predetermined diameter, variations in the thread length of at least 10% have nevertheless occurred. In. operations like warping, such a deviation in thread length is execessive, and causes a large amount ofwaste. The undesirable variation in the thread length is attributable to various factors. One of these factors is the variable pressure with which the reciprocating thread feed mechanism rests on the thread package during winding. Another factor which causes uneven thread United States Patent lengths is the moisture content of the thread. This, of 1 course, is because threads containing a relatively higher moisture content are more easily flattened. Additionally, the variation in the denier, or fineness of the thread which is used in the winding operation can cause differences in the. length of thread applied to the various cones.

All of these factors contribute to the formation of thread packages which have identical diameters and different thread lengths.

Accordingly, therefore, the present invention contemplatesa method and apparatus for obtaining thread packages with substantially the same length of thread wound upon each cone. In accomplishing this, the use of the ultimate diameter of the package as the sole controlling variable is discarded, and there is substituted the total number of revolutions of the cone winding spindle. As will be explained more fully below, the total number of such revolutions will include one or more correction factors which alter the speed at which a revolution counter registers the spindle revolutions.

In practicing the invention, the threads are continuously wound during a first interval until the thread package attains a first predetermined diameter D The first predetermined diameter D, is empirically determined and comprises the outside diameter of a thread package which contains the desired lineal yardage of thread applied at The average outside diameter of a plurality of thread packages which have all been wound at approximately the same maximum compactness may be used in fixing the value of D For purposes of this specification this diameter characterizes what is known as the most compact cone. The abbreviation MCC as used in this specification will refer to the latter mentioned most compact cone.

If the number of revolutions counted at the instant a,

2 particular thread package arrives at the first predetermined diameter D 1 is less than the value usually attained by the most compact cone (MMC) for the same desired length, of thread, the winding operation is continued. Beyond this point, however, of spindle revolutions is not counted. Rather, by means of changing the gear ratio between spindle and counter a. higher value is registered. This higher value constitutes the actual revolutions multiplied by a constant factor.

0 This constant factor is equal to the ratio (Lg/L1) and is usually greater than 1. The numerator L is the average length of a thread coil in the range between the diameter of the most compact cone (MMC) at the desired thread length and the diameter of an equally long thread coil on a package of the most usually found compactness. The denominator L is the length of a thread coil at half the radial thickness ofthe thread package attained in winding the package to the first predetermined diameter D The use of the ratio is best seen from the following equation:

LaAddltlonal num- (I) Number of revolu- Number of revottons required for f, her of revolutions lutions required to present cone to wind desired length reach D1 on M00 or (11) m +(LaIL1)m m In winding cones according to this equation, the

right-hand term represents the number of revolutions of the cone winding spindle which are required to wind the requisite length of thread on a most compact cone (MCC). This value is readily obtainable by simple measurement. A revolutions counter is set at this value and stops the winding machine when this number-of revolutions is reached.

The first bracketed term on the left side of the equation represents the number of revolutions required for the diameter of the cone which is being wound to attain the value D as earlier defined. When this value is sensed, the gear ratio between the cone winding spindle and revolution counter is changed to provide the value of the coefficient (L /L which precedes the second bracketed term on the left-hand side.

Hence, with the revolution counter set to halt the winding operation as soon as the value it, is reached, and proper mechanism for interposing the gear ratio (L /L between the spindle and the revolution counter when the diameter D, is reached, age continues only until the desired length of thread has been applied. In summary, the method and apparatus of the present invention includes the following sequence of operations: The number of revolutions of the cone win-ding spindle are accurately counted, and the winding operation is interrupted'at a predetermined package diameter. After this interruption, the remaining revolutions are counted in an accelerated manner by altering the gear ratio. Then, the operation is cut-off at the final registered number of revolutions, to provide cones of equal thread length and varying diameters.

Accordingly, therefore, a primary object of the present invention is to provide a novel apparatus and method for winding substantially constant yardage on each of a plurality of thread packages.

Another object of the invention is to teach an ingenious mechanism for terminating the winding operation on each of a series of individual thread packages when a predetermined length of thread has been applied thereto.

Another object of the present invention is to dis close a method and means for accurately controlling the length of thread applied winding machine.

Still another object of the present invention is to teach a stepwise method of continuing the winding of a thread- .Patented Feb. 3, 1959 the actual number 1 the winding of each thread packto thread packages by a crosspackage in order to accurately apply a predetermined length of thread thereto.

A further object of the invention is to disclose a subbecome evident through reference to the following description and drawings like parts and in which:

Figure 1 illustrates diagrammatically the relationship between the diameter of any given thread package and the length of the corresponding particular thread coil.

Figure 2 is a perspective view, in elevation and partly in section, showing a portion of a cross-winding machine operated according to the method of the present invennon.

Figure 3 is a fragmentary plan view, partly in section, illustrating a portion of the cross-winding machine shown in Figure 2, and in particular the system used for changing the speed ratio between the spindle of the winding machine and the revolution counter.

Turning now to Figure 1, there is shown diagrammatically the relationship between the length and diameter of a thread package. This diagram will be utilized of the present invention.

In the diagram, there are shown several values of diameter along the horizontal axis. The point D corresponds to the average length of a thread coil laid directly upon the periphery of a cone. D corresponds to the diameter at which the most compact cone (MCC) attains the desired value of thread yardage. This diameter is reached after 11 actual revolutions of the spindle, and is the value at which the revolution counter must be set, in accord ance with the Equation I as explained earlier in this specification. The length of the last thread coil on such a package is indicated by that value of L on the ordinate which corresponds to the outside diameter D for the most compact coil (MCC).

The value D shown on the horizontal axis is the diameter of a thread package which is wound to the same total length L with the minimum compactness observed in actual practice. This value of diameter D may comprise the mean or average diameter of several thread packages wound with approximately the least dense packing, or minimum compactness encountered. A thread package of such diameter requires n actual revolutions of thread upon the cone.

Assume that it is desired tions intermediate between the value n; which characterizes D and the value 11 which characterizes D and least compact package, the required number of revolutions will generally be less than 12 with intermediate compactness will eter of the package required to achieve a given yardage increases as the degree of compactness decreases. causes the length convolution to exceed that found a value D at the mean diameter of the cone length L. In general, some value of revolutions (say n is required to wind the given thread package to this diameter.

The length of the thread windings on this package vary from layer to layer. However the average length L may be considered to be constant. This is true if the winding of the thread package originates at the average diameter of the axially tapered cone used to support the threads. In other must. start at the mean diameter of the cone in order for the value L to remain constant. This diameter is designated as D and is the ordinate which occurs exactly at the origin of the graph shown in Figure l. Stated mathematically, the length L is constant where mate value of outside diameter D It is significant that the constant factor L is not dependent upon the degree of compactness of the package. the thread upon the cone up to homogeneous, the length L; shown in Figure l is the lineal yardage of 'a thread winding one-half the radial thickness of the annular thread package out to this diameter. Where the degree of homogeneity varies linearly or systematically, other values of L may be employed.

In general, unless the density of the thread package bethe winding in the interval package has received sarily higher than u because up to D is less compact, and the a resultingly shorter thread length. Turning again to Figure l,

the winding operation continues after a package of inhas attained the diameter D a length of thread having a is no longer applied. Assume desired revolutions (n is 11 additional revolutions of thread to reach a greater diameter D Then, with the predetermined length L attained, there will exist an ordinate L in Figure l which corresponds to the average length of the thread coils applied to the cone after it has reached the diameter D In winding such a thread package the attainment of the diameter D; has required a length of thread equal to (n XL with continued winding the ultimate reaching of the desired length L has required an additional length equal to (n L It therefore follows that:

3 1)+( 4 2)= for, rearranging terms (W) 3+ (L2/L1')"4=(L/L1) In the last written equation, the right-hand term (L/L is a constant. The numerator L represents the constant value of yardage desire-d on every cone. The denominator L comprises the average thread length of thread coils attained in winding the package up to a diameter D Moreover, the quotient (L/L is identically equal to the value of revolutions n required to attain diameter D on a most compact cone (MCC).

termediate compactness (at 11 actual revolutions It is desirable to eliminate the variable L in the EquationIV. Generally, L may not be completely constant because of the fact that D varies. The substitution of a variable L in place of L has been found to yield an acceptable degree of accuracy.

This quantity L is defined as the average length of thread coils of the proper length which occur between diameter D, on the most compact coil, and the diameter D; of coils of the same length which occur on thread packages with the most frequently encountered degree of compactness.

The diameter D.,,, like the diameters D and D may be determined empirically by securing a mean value from a plurality of thread packages characterized by substantially the most frequently occurring degree of. compactness. By substituting L for L and n for the ratio (L/L Equation IV now reads:

0 "ma Lemma -In Equation V the values L and L are readily obtainable by simple measurement at the value of yardage L decided upon for a particular run. The significance of Equation V is brought out by substituting the verbal equivalents therein as follows:

Number of revo- Numb cr of revolutions L3 Additional required for present L number of revolutions required to cone to reach D1 2 lutions wind desired length on MOO This, of course, is Equation 1, as originally set forth in the introductory portion of the specification.

' It will be appreciated that the present invention teaches a system for conducting the winding operation in accordance with the above-mentioned equation. The computation of Equation V is carried out automatically. While the specific system illustrated in the drawings is a mechanical system, the invention is by no means limited thereto. It will be understood that the inventive method disclosed herein is equally amenable to practice with hydraulic or electronic systems, and is entitled to a broad range of equivalents.

In the mechanical embodiment described in this specification, the spindle of the winding machine is coupled to a revolution counter via a controllable gear ratio system. Control means are provided for shifting the gear ratio between the spindle and counter in response to the arrival of the thread package at the predetermined diameter. Additionally, means are provided for halting the winding operation when a preset number of revolutions is ultimately registered on the counter. For this purpose, the counter is provided with a cam which controls a disconnecting mechanism between the machine spindle and its drive motor, as will be explained more fully below.

Continuing now with this aspect of the detailed description of the invention, and more particularly with the view thereof shown in Figure 2, the numeral 1 indicates generally a cross-winding machine which is used for applying a plurality of layers of thread to an axially tapered cone.

In the winding machine generally indicated by reference numeral 10, a cone 11 is securely mounted upon the winding spindle 12 for rotation therewith. The winding spindle 12 is rotatably supported by the frame 13 of machine and may be driven by belt 14 which engages drive roller 15. During a winding operation the belt 14 is maintained in frictional contact with drive roller 15 by pressure roller 16, which pressure roller is freely rotatably mounted on one end of double-armed lever 17. Atension spring 18, one end of which is secured to the frame 13 and the other end of which is attached to double-armed lever 17, resiliently urges pressure roller 16 into the inoperative position, as shown by broken lines in the drawing.

The double-armed lever 17 is rigidly attached to one end of an elongated shaft 20. This shaft extends parallel to winding spindle 12 and is also freely rotatably sup,- ported from frame 13. A switching lever 21 is rigidly secured to that end of shaft 20 remote from the doublearmed lever 17. The switching lever 21 is generally in the shape of a bell-crank, having a handle portion 22 used for manually setting or re-setting pressure roller 16 in operative position and a curved arm 23, on the outer end of which is formed a projection 24.

A latch mechanism 25, pivotally mounted at 26 to winding machine It), comprises an upper arm 27, on the end of which is formed hook 28, and a lower arm 30. The hook 28 cooperates with projection 24 on the curved arm of switching lever 21 and locks said lever, shaft 20 and double-armed lever 17 against rotation due to the action of tension spring 18, as can be seen upon inspection of Figure 2. Upon movement of latch mechanism 25 to the broken line position shown, by mechanism to be described more thoroughly hereinbelow, it can be seen that hook 28 will release the projection 24 and that, as a result thereof, pressure roller 16 will be shifted into inoperative position, which discontinues the drive between belt 14- and drive roller 15.

Although the above-described release of switching lever 21 results in an immediate interruption of the drive for Winding spindle 12, the same would continue to rotate by virtue of momentum, and, therefore, cone 11 would continue to receive thread, unless preventative measures were taken. Accordingly, a brake disc 31 is fixed to winding spindle 12, which disc cooperates with brake shoe 32. One end of this brake shoe is pivoted to the frame 13, by means not shown, and the other end is pivoted at 33 to the hub of switching lever 21. This results in a toggle arrangement, operative upon release of projection 24 to force brake shoe 32 into engagement with disc 31, which stops rotation of winding spindle 12 immediately upon interruption of the drive couple.

A traversing frame 34 is pivotally mounted at 35 to the winding machine and provided with a weight 36 at the lower end thereof. On the upper end of the traversing frame a thread guide 37 is mounted for reciprocatory movement, this being accomplished by known traversing mechanism not here shown. The thread guide 37 is urged lightly against the cone 11 and the thread package 38 collected thereon during Winding by virtue of the weight 36. inasmuch as that portion of the winding machine de scribed hereinabove is conventional, further details as to structure and operation will be omitted.

With attention momentarily directed to Figure 3 of the drawings, it will be noted that the portion of Winding spindle 12 which is remote from the cone 11 is provided with a square cross-section 40. A drive gear 31, shown in section, is non-rotatably but slidably positioned upon section 40 and therefore is axially movable with respect thereto. Immediately adjacent to drive gear 41 there is provided an annular bushing 42 and a pinwheel 43. The gear 41, bushing 42 and pinwheel 43 are secured together and movable as a unit along the axis of the winding spindle.

Extending axially from the pinwheel 43 are a pair of pins 44. Upon axial movement of gear 41 the pins 44 are caused to engage or disengage a corresponding pair of apertures 45 in driven gear 46. In the position shown, drive gear 41 engages a first intermediate gear 47 which is fixed to idler shaft 48. Also fixed to idler shaft 43, but displaced axially from gear 47, is a second intermediate gear 5i Both of these intermediate gears 47, 50 are keyed or otherwise secured to the shaft 48, and the shaft is journaled for rotation between suitable bushings 51, 52, provided in the housing 53.

In one position of adjustment, drive gear 41 engages first intermediate gear 47 and, through idler shaft 48 and second intermediate gear 50, positively rotates driven gear 46 at a first rate of speed, gear 50 being at all times in mesh with driven gear 46. In the alternative position of aeemeo the same does not mesh with is rotated, through pinwheel 43, at the identical speed as that of winding spindle 12.

revolutions exclusively, indexes a new digit only her of times.

With attention now directed both Figure 3, it will be seen that cam disc operates with a follower 57 fixed, shown, to one end of a first Bowden posite end of cable 58 is pivotally coupler 69, to the lower arm 34) of latch mechanism 25, as shown in Figure 2. Movement of the latch mechanism 25 into the broken line position, which releases the switching lever 21 as explained hereinabove, therefore is accomplished by cam disc 56 through cable 58. Hence, upon arrival of circumferenthe drive for winding spindle 12 is immedito Figure 2 and to 56 engages and coin the embodiment cable 53. The opconnected, through compact cone (MCC). revolutions has been reached, the cam disc follower 5'7 of the annular I V the annular space between these elements makes possible the axial shifting of the entire assembly in unison with movement of the lever. More particularly, the oscillation of lever 61 about pin 62 in the counter-clockwise direcment of parts, drive with first intermediate gear 47, which dlsconnects this gear train.

f the package in? about pivot 35 with the thread. As the diameter ea s h me 4 i gra ua ly moved,

I spindle lz and cone 11. When the package attains the predetermined diameter, the outer face of I depresses the feeler 63. 63, in the embodiment shown, is attached to or formed integrally with one end of a second Bowden cable 64, as

shown in Figure 2. Upon inspection of Figure 3 it will reaches the required diameter D In starting a winding operation according to this invention, an empty cone 11 is placed upon the spindle 12 and the revolution counter 55 is adjusted to register a value wise direction, as viewed in Figure 2. At the instant of arrival at the preset diameter, the frame 34 engages the feeler 63 and transmits a thrust through cable 64 and pin 65, to the selector lever 61. As previously pointed the most compact served in actual practice. Upon the aforesaid sequence of events occurs and the selector lever shifts the drive gear 41 along the axis of spindle 12, nd drive 44, 45 thus increasing the gear ratio between counter 55 and spindle 12.

The winding operation now continues with the revolution counter 55 counting the spindle revolutions at a higher rate than before. As soon as the her of revolutions has occurred, the cam disc 56 actuates follower 57 and transmits Bowden cable 58, which shifts the latch mechanism 25 into the broken line position of Figure 2. lease of the projection 24 from hook 28, by spring 18,

which, as explained, rotation of the spindle 12. The number of revolutions required to discontinue the application of thread to cone 11 is, of course, the preset value which was set upon the counter 55 prior to the beginning of winding.

By using the apparatus and method disclosed herein, the variations in thread length between a plurality of thread packages approximates 1%.

While the subdivision of two steps has been disclosed,

the inventlon is not thus limited. The winding operaoperation,

the spindle and the revolution counter. this would appear as:

In this equation, n n ng, and (L /L have the same meaning as before. However, a, and u are the additional number of revolutions required to spin the counter to the present value m The constants k and k' are-the new quotients, or gear ratios required to be successively interposed It will be appreciated that the new gear ratios may occur stepwise in discrete steps, or stepless, as with a mechanical variator or other type of infinitely variable speed changer.

In each of these additional steps a new average thread coil is taken as the basis for the changed gear ratio between the spindle and the revolution counter. In this the subsequent speed ratios are maintained as closely as possible to the actual average length of the thread coils. By thus employing a series of changed gear ratios to accelerate the counting of the revolutions up to the ultimate value, the deviations in yardage may be reduced below the value of 1% previously mentioned in the specification.

In practicing the multi-step aspect of the invention, a stepwise change gear between spindle and counter may be used. The actuation of the subsequent gear changes may be accomplished in response to the several successively larger diameters attained by the thread package during winding. Or, acontrol mechanism which is actuated by the spindle itself may be used to initiate the successive changes in thegear ratios.

Alternatively, the system may employ a combined change drive gear which shifts through the series of steps after the first one by successive smooth steps which merge imperceptibly into each other. A mechanical variator may be used for this purpose.

In using the combined change drive gear, the diameter of the thread package may be used to initiate the change in speed ratio required upon arrival at diameter D,, and the spindle shaft itself may be used to control the subsequent smooth steps. If desired, the thread package diameter may be periodically sensed by suitable means which initiate the successive imperceptible steps.

It will also be appreciated that throughout the specification the term winding machines has been used broadly to include devices such as warping machines and the like. Also, the term thread as used herein is not limited to the flexible elongated fibers characteristic of the textile industry but encompasses metallic threads such as wires or strands and the like.

In conclusion, it will be evident from the foregoing detailed description and drawings that I have clearly disclosed my invention in compliance with the statute. However, it is further evident that various modifications, substitutions and alterations can be made Without departing in any manner from the spirit and scope of the appended claims.

What I claim is:

1. In a cross-winding machine provided with an interruptable drive means, spindle means to support a cone during the winding of a circular thread package, means mounted to deflect as the size of said package increases, means connected to count revolutions and interrupt said drive means of said winding machine at a preset value of total revolutions, and means connected between said spindle means and said counting means to accelerate the rate of counting revolutions as soon as said deflecting means detects a preset diameter.

2. In a machine adapted for winding circular thread packages and provided with an interruptable torque supply, means rotatably mounted upon said machine and supporting at least one cone during the application of said thread package thereto, means mounted to deflect as the size of said package increases, means to count Mathematically,

between thespindle and the counter.

assures revolutions ateither oftwo rates neans connected to said counting'means to interrupt said-torque supply at a preset number of revolutions, and means responsive to said deflecting means to effect a change in the rate of counting after the attainment of a preset package size.

3 ."11'1 a cross-widing machine provided with drive means for supplying an interruptable supply of. torque, a spindle mounted to support a cone during the formation of a thread package thereupon, a revolution counter, means operable to interrupt said supply of torque in response to the arrival of said counter at a predetermined ultimate value, a variable ratio gear train mechanically interposed between said spindle and said counter for controlling the rate at which said counter registers revolutions, means to sense the increasing diameter of said thread package during the winding operation, and means responsive to said diameter sensing means for changing the gear ratio between said spindle and said counter when said thread package attains a predetermined diameter.

4. In a machine which is provided with interruptable drive means and equipped to wind a thread package upon a cone, means connected to support said cone and rotate, therewith, means connected to continuously deflect as a dimension of said thread package increases, means connected to meter the number of revolutions of said support means, means mounted upon said metering means to interrupt said drive means in response to the occurrence of a preset number of revolutions, and means interposed between said support means and said metering means to change said interposed means operative only in response to dc tection of a preset dimension of said thread package by said deflecting means.

5. In a winding apparatus provided with drive means and adapted for applying a predetermined length of thread to a cone, a spindle mounted to revolve with said cone during the winding of a thread package thereupon, a first gear slidably mounted on the end or said spindle remote from said cone, a pinwheel slidably mounted upon said spindle for axial displacement with said first gear, a plurality of pins secured to and angularly spaced about the axis of said pinwheel, a revolution counter, a second gear mounted to drive said revolution counter and provided with a plurality of angularly spaced holes, each of which is adapted to receive a respective one of said pins, a shaft rotatably mounted parallel to said spindle, a third gear secured to said shaft and mounted to fully engage said first gear only when said angularly spaced pins remain free of said angularly spaced holes, a fourth gear secured to said shaft and mounted to engage said second gear, means connected to slide said angularly spaced pins into registry with said angularly spaced holes in said second gear as soon as said thread package attains a predetermined diameter, and means connected to interrupt the application of torque to said machine and halt the winding operation as soon as said counter registers a preset number of revolutions thereupon.

6. The method of winding a predetermined length of thread on a cone which comprises winding a thread package on the cone up to the point at which a preset diam eter is reached while counting the revolutions of the cone, and continuing the winding operation beyond the preset diameter in at least one more step while counting revolutions at an accelerated rate during each-step beyond the point where the preset diameter has been reached.

7. The method of winding a predetermined length of thread on a cone which comprises applying successive layers of thread upon said cone up to a predetermined diameter while simultaneously counting the nu ber of times that the cone supporting spindle revolves, accelerating the rate of counting the spindle revolutions during the interval following the attainment of the predetermined diameter while simultaneously applying addithe rate of counting revolutions,

i a l y r of thread, and. terminating the application of thread to said cone as soon as said spindle has described a predetermined number of revolutions.

8. The method of winding a predetermined length of thread into package form which comprises applying a plurality of layers of thread to a rotating cone, counting f and terminating the winding operation after a predeter mined total count.

References Cited in the file of this patent UNITED STATES PATENTS 743,961 Walker t- Nov. 10,1903 1,033,855 7 Wilson July 30, 1912 2,131,086 Armett et a1 -Sept. 27, 1938 

